Global monitoring system for critical equipment performance evaluation

ABSTRACT

Acquiring and evaluating data regarding the performance of critical equipment of various business units distributed around the globe is essential in today&#39;s market. In particular aggregating, organizing and evaluating various types of data at a host processing system that is accessible via an intuitive graphical user interface to approved users connected to an enterprise network.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional application which claims benefitunder 35 USC §119(e) to U.S. Provisional Application Ser. No. 62/222,561filed Sep. 23, 2015, entitled “GLOBAL MONITORING SYSTEM FOR CRITICALEQUIPMENT PERFORMANCE EVALUATION,” which is incorporated herein in itsentirety.

FIELD OF THE INVENTION

This invention relates to apparatus and method for acquiring andevaluating data regarding the performance of critical equipment ofvarious business units distributed around the globe. In particular, theinvention concerns aggregating, organizing and evaluating various typesof data at a host processing system that is accessible via an intuitivegraphical user interface to approved users connected to an enterprisenetwork.

BACKGROUND OF THE INVENTION

Large businesses may include various business units based around theglobe. Some or all of the business units may operate equipment andsystems that are economically vital or critical to the parent business.Sudden unexpected shutdown of such equipment and associated systems mayprove to be detrimental to the parent business. Hence, parent businesseswould appreciate developments in apparatus and methods that wouldprevent or limit unplanned shutdowns of critical equipment.

SUMMARY OF THE INVENTION

An method for aggregating and evaluating data of equipment operated by aplurality of business units, the method comprising: sensing parametersof the equipment using a sensor to provide sensor data; receiving thesensor data using a plurality of business unit historian processingsystems, each business unit historian processing unit being associatedwith each of the business units in the plurality of business units andconfigured to label equipment being monitored by the sensor with ageneral description and a specific description that is more specificthan the general description; transmitting the sensor data to a hostprocessing system via an enterprise network of a parent business of theplurality of business units; transmitting equipment data from an outsidebusiness processing system of an outside business that is not affiliatedwith the parent business to the host processing system via theenterprise network; aggregating (i) the sensor data received from eachof the business unit historian processing systems associated with eachof the business units and (ii) the equipment data into a data base usingthe host processing system; evaluating the sensor data and the equipmentdata using the host processing system to provide an equipment evaluationfor the equipment associated with each business unit using the hostprocessing system; receiving a request, using the host processingsystem, for the sensor data, the equipment data, and the equipmentevaluation associated with specific equipment at a specific businessunit from a user using a user interface that implements a graphical userinterface (GUI), the GUI comprising an image mimicking the equipment,the user processing system comprising a search engine configured tosearch for monitored equipment using at least one of the generaldescription and the specific description; and transmitting the sensordata, the equipment data, and the equipment evaluation associated withthe specific equipment at the specific business unit to the userprocessing system in accordance with the request.

A global monitoring system for aggregating and evaluating data ofequipment operated by a plurality of business units, the systemcomprising: a plurality of sensors configured to sense parameters of theequipment to provide sensor data; a plurality of business unit historianprocessing systems configured to receive the sensor data, each businessunit historian processing system being associated with each of thebusiness units in the plurality of business units and configured tolabel equipment being monitored by the sensor with a general descriptionand a specific description that is more specific than the generaldescription; an enterprise network of a parent business of the pluralityof business units, the enterprise network being configured tocommunicate with the plurality of business unit historian processingsystems; a host processing system in communication with the enterprisenetwork and configured to receive the sensor data from each of thebusiness unit historian processing systems and equipment data from anoutside processing system of an outside business that is not affiliatedwith the parent business; a user processing system in communication withthe host processing system via the enterprise network and comprising agraphical user interface (GUI), the GUI comprising an image mimickingthe equipment, the user processing system comprising a search engineconfigured to search for monitored equipment using at least one of thegeneral description and the specific description; wherein the hostprocessing system is further configured to: aggregate (i) the sensordata received from each of the business unit historian processingsystems associated with each of the business units and (ii) theequipment data into a data base; evaluate the sensor data and theequipment data to provide an equipment evaluation for the equipmentassociated with each business unit using the host processing system;receive a request for the sensor data, the equipment data, and theequipment evaluation associated with specific equipment at a specificbusiness unit from a user using the user processing system; and transmitthe sensor data, equipment data, and equipment evaluation associatedwith the specific equipment at the specific business unit to the userprocessing system in accordance with the request.

Sensor data may be transmitted to the outside business processingsystem, wherein the outside business processing system evaluates thesensor data and provides an outside equipment evaluation as theequipment data.

Evaluating includes comparing the sensor data or the equipment data to athreshold value.

Alert signals may be initiated if the sensor data or the equipment dataexceed a threshold value. The alert signal may also be transmitted tothe user processing system.

A work order to repair or service the equipment may be generatedcorresponding to the sensor data or the equipment data if the sensordata or the equipment data exceed the threshold value. Additionally, thework order may be transmitted to the business unit having the equipmentcorresponding to the sensor data or the equipment data. Finally, theequipment corresponding to the sensor data or the equipment data may berepaired in accordance with the work order.

Business unit historian processing systems may be updated with latestsensor data and latest equipment data in real time.

General description may include a function of the correspondingequipment and the specific description comprises a make and model of thecorresponding equipment.

A search of the business unit historian processing system may besearched using the search engine in the host processing system inresponse to a request by a user using the user processing system.

The enterprise network may be configured to transmit the sensor data tothe outside business processing system, wherein the outside businessprocessing system evaluates the sensor data and provides an outsideequipment evaluation as the equipment data.

The host processing system may be configured to compare the sensor dataor the equipment data for specific equipment to a threshold value. Inaddition, the host processing system may be configured to initiate analert signal if the sensor data or the equipment data for specificequipment exceeds the threshold value. The host processing system mayalso be configured to transmit the alert signal to the user processingsystem. The host processing system may initiate a work order to repairor service the specific equipment corresponding to the sensor data orthe equipment data if the sensor data or the equipment data exceeds thethreshold value. Finally, the host processing system may transmit thework order to the business unit having the specific equipmentcorresponding to the sensor data or the equipment data.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention, together with further advantages thereof, may best beunderstood by reference to the following description taken inconjunction with the accompanying figures by way of example and not byway of limitation, in which:

FIGS. 1A and 1B, collectively referred to as FIG. 1, depict aspects of aglobal monitoring system operated by a parent business;

FIG. 2 depicts aspects of one embodiment of a graphical user interface;

FIG. 3 depicts aspects of one embodiment of the global monitoringsystem;

FIG. 4 is a block flow diagram of one embodiment of a process monitoredby the global monitoring system;

FIG. 5 is a flow chart depicting aspects of various functions of theglobal monitoring system; and

FIG. 6 is a flow chart for a method for aggregating and evaluatingequipment data from a plurality of distributed business units.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to embodiments of the invention,one or more examples of which are illustrated in the accompanyingdrawings. Each example is provided by way of explanation of theinvention, not as a limitation of the invention. It will be apparent tothose skilled in the art that various modifications and variation can bemade in the present invention without departing from the scope or spiritof the invention. For instance, features illustrated or described aspart of one embodiment can be used on another embodiment to yield astill further embodiment. Thus, it is intended that the presentinvention cover such modifications and variations that come within thescope of the appended claims and their equivalents.

Disclosed are apparatus and methods related to a global monitoringsystem operated by a parent business for aggregating and evaluatingequipment data from a plurality of distributed business units. Theglobal monitoring system drives improvement in the operating performanceof business unit facilities through interactive decision support oftheir critical equipment. This monitoring system is enabled through a“host” attached to an enterprise network of the parent business, andlinked to each business unit facility's data historian. The host isconfigured to use graphical user interfaces (GUIs) to access clientservices and internal reporting data bases. It enables the globalmonitoring system to function as a collaborative platform for thepurpose of analyzing and improving facility and equipment performance.

The global monitoring system can generate facility and equipmentperformance indicators by processing input variables from each businessunit's data historian. These indicators can display performance trendsand identify value improvement opportunities for facilities and theirequipment. GUI programming allows enterprise-wide web access to theseindicators to promote collaboration among the business units and centralfunctions and to leverage best practices in use by the business units.

The global monitoring system can drive increased proficiency in threefundamental areas of equipment performance assurance to addressperformance gaps and improve equipment operation. The three fundamentalareas are: (1) anomaly recognition—identifying unusual equipmentoperation to understand and mitigate potential failure modes; (2)performance analysis—modeling equipment operation in comparison to itsnameplate capacity to diagnose and characterize performance degradation;and (3) condition monitoring—field verification of critical indicatorsin comparison to established limits of reliable operation.

Further, the global monitoring system can access in-house systems andcommercially-available client services performed by outside businessesfor collaborative viewing and interaction through global monitoring todrive proficiency in each of the three fundamental areas in the businessunits' systems.

Turning now to FIG. 1, aspects of a global monitoring system 10 operatedby a patent business are depicted. In FIG. 1A, a simplified drawing of amonitored process and a monitored machine is presented. A first sensor 1is coupled to process piping 3 for monitoring a fluid 4 disposed in thepiping 3. The first sensor 1 is configured to sense a property ofinterest of the fluid 4. Non-limiting embodiments of the sensed propertyinclude temperature, pressure, flow rate, density, viscosity, radiation,and chemical composition. A second sensor 2 is coupled to a machine 5for monitoring a property of the machine 5. Non-limiting embodiments ofthe sensed property of the machine 5 include mechanical properties suchas temperature, vibration or acceleration, oil level, coolant level,speed, and/or electrical properties such as current and voltage. Sensedproperty values from the first sensor 1 and the second sensor 2 aretransmitted to a processing system 6 at the business unit (BU) levelreferred to as the business unit historian processing system (BUHPS) 6.At the BUHPS 6, the sensed property values are stored along with a timeat which the sensed values were received. It can be appreciated that thesensed property values may be transmitted in real time (e.g., as soon asthe measurement is performed) to the BUHPS 6. The BUHPS 6 may also labelsensed data with a general description, such as compressor or pump forexample, and a specific description, such as make and model of theequipment being monitored. In general, the specific description containsmore specific detail regarding the monitored equipment than the generaldescription. This enables various levels of searches to suit therequirements of a user.

In FIG. 1B, three BUHPS's are illustrated for teaching purposes, theBUHPS 6 illustrated in FIG. 1A and two other BUHPS's (BUHPS 7 and 8)receiving sensed property values from monitored equipment. In general,the business units associated with the BUHPS's are differentiated bytheir geographical location. Each of the BUHPS's is connected to anenterprise network 9. The enterprise network 9 in general is operated bythe parent business of the business units. Communications with theenterprise network 9 may be by way of the Internet, a parent businessintranet, hardwire, telephone line, radio or any other ways known in theart. Also connected to the enterprise network 9 is a host processingsystem 11 and a plurality of user processing systems 12. The hostprocessing system 11 is configured to retrieve data from each of theBUHPS's. In addition, the host processing system is configured toreceive data from an outside business processing system 13 operated byan outside business to evaluate specific processes and machines atspecific business units. In general, the outside business is not part ofor affiliated with the parent business and may perform “client services”using proprietary algorithms or techniques under contract to the parentbusiness or one of the business units. In one or more embodiments, theoutside business may communicate with the host processing system usingthe Internet. Further, the host processing system is configured toevaluate sensor data such as by comparing the sensor data to a thresholdlevel, setpoint, or range of values. The threshold level, setpoint, orrange of values may be determined by experience, by an equipmentmanufacturer or by an algorithm modeling the operation of a process ormachine. Further, the host processing system may be configured toevaluate any data or evaluations received from the outside business. Inresponse to any evaluation, the host processing system may be configuredto send an alert signal to users of the business unit having the processor machine of interest or other users entered into the host processingsystem as having an interest in the process or machine associated withthe evaluation. In one or more embodiments in response to anyevaluation, the host processing system may be configured to send a workorder authorizing repair or servicing of the process or machineassociated with the evaluation.

Each user processing system 12 is configured to query the hostprocessing system 11 to request sensor values or information concerninga specific process or machine at a specific business unit. In one ormore embodiments, each user processing system 12 includes a searchengine to perform queries. The information may include evaluationsperformed by the host processing system or data or evaluations performedby an outside business. Each user processing system may include agraphical user interface (GUI) to aid the user in requesting sensorvalues or information of interest. In one or more embodiments, the GUIprovides an image that mimics the process or machine of interest withtext boxes for providing data associated with a portion of interest.FIG. 2 illustrates one example of a GUI 20 for a turbine machine 21. TheGUI includes text boxes 22 for displaying a label identifying themachine being monitored, data values, and units of the data values. Ingeneral, the text boxes 22 are located in the vicinity of or connectedto the portion on interest of the process or machine to which the datacorresponds. In one or more embodiments, a color indicator 23 isassociated with each text box 22. The color indicator 23 is configuredto display a color corresponding to a status of the current data in thetext box 22. In one or more embodiments, the colors are green for normalvalues of the data, yellow for data values in a caution zone, and redfor data values in a zone of concern. It can be appreciated that othercolors may also be used for these or other purposes.

FIG. 3 depicts aspects of another embodiment of the global monitoringsystem 10. In the embodiment of FIG. 3, a firewall 30 is disposedbetween the host processing system and the enterprise network.Similarly, the firewall 30 is disposed between a business unit historianprocessing system and a business unit enterprise network. Users at thebusiness unit level can access the BUHPS or the host processing systemvia the business unit enterprise network. Also illustrated in FIG. 3 isa supervisory control and data acquisition (SADA) system 31 forproviding sensor data to a BUHPS. The SCADA system in the embodiment ofFIG. 3 includes a radio communication system 32.

FIG. 4 is a block flow diagram of one embodiment of a process 40 atFacility XXX monitored by the global monitoring system 10. The process40 includes a Separator A that supplies fluid to a Compressor Train Zthat in turn provides a fluid to Exchanger Y. Process sensors 8 andmachine sensors 9 are used to monitor the process 40. FIG. 5 is a chartdepicting aspects of various functions of the global monitoring system(GMS) 10 for monitoring the process 40 illustrated in FIG. 4. In theembodiment of FIG. 5, the GMS 10 performs a performance analysis ofvarious rotating equipment for all of the business units connected tothe enterprise network using condition monitoring guidelines and anomalyrecognition guidelines. The GMS 10 in FIG. 5 also monitors the metricsof Facility XXX to include Exchanger Y performance metrics, Compressor Ztrain performance metrics to include Compressor Z and Turbine Z (notshown) performance metrics.

Turning now to FIG. 6, a flow chart for one example of a method 60 foraggregating and evaluating data of equipment operated by a plurality ofbusiness units is presented. Block 61 calls for sensing parameters ofthe equipment using a sensor to provide sensor data. Block 62 calls forreceiving the sensor data using a plurality of business unit historianprocessing systems, each business unit historian processing unit beingassociated with each of the business units in the plurality of businessunits and configured to label equipment being monitored by the sensorwith a general description and a specific description that is morespecific than the general description. In one or more embodiments, thegeneral description includes a function of the monitored equipment andthe specific description includes a make and model of the monitoredequipment. Block 63 calls for receiving equipment data from an outsidebusiness processing system of an outside business that is not affiliatedwith a parent business of the plurality of business units using theplurality of business unit historian processing systems. In one or moreembodiments, each of the business unit historian processing systems isupdated with latest sensor data and latest equipment data in real time.Block 64 calls for transmitting the sensor data and the equipment datato a host processing system via an enterprise network of the parentbusiness. Block 65 calls for aggregating (i) the sensor data receivedfrom each of the business unit historian processing systems associatedwith each of the business units and (ii) the equipment data into a database using the host processing system. Block 66 calls for evaluating thesensor data and the equipment data using the host processing system toprovide an equipment evaluation for the equipment associated with eachbusiness unit using the host processing system. Evaluating may includecomparing the equipment data or the other equipment data to a thresholdvalue or a range of reference values. Block 67 calls for receiving arequest, using the host processing system, for the sensor data, theequipment data, and the equipment evaluation associated with specificequipment at a specific business unit from a user using a user interfacethat implements a graphical user interface (GUI), the GUI comprising animage mimicking the equipment, the user processing system comprising asearch engine configured to search for monitored equipment using atleast one of the general description and the specific description. Block68 calls for transmitting the sensor data, the equipment data, and theequipment evaluation associated with the specific equipment at thespecific business unit to the user processing system in accordance withthe request.

The method 60 may further include transmitting the sensor data to theoutside business processing system, wherein the outside businessprocessing system evaluates the sensor data and provides an outsideequipment evaluation as the equipment data. The method 60 may furtherinclude initiating an alert signal if the sensor data or the equipmentdata exceed the threshold value. The method 60 may further includetransmitting the alert signal to the user interface. The method 60 mayfurther include initiating a work order to repair or service theequipment corresponding to the sensor data or the equipment data if thesensor data or the equipment data exceed the threshold value. The method60 may further include transmitting the work order to the business unithaving the equipment corresponding to the sensor data or the equipmentdata. The method 60 may further include repairing or servicing theequipment corresponding to the sensor data or the equipment data inaccordance with the work order. The method 60 may further includeperforming a search of the business unit historian processing systemusing the search engine in the host processing system in response to arequest by a user using the user processing system.

In support of the teachings herein, various analysis components may beused, including a digital and/or analog system. For example, the firstsensor 1, the second sensor 2, the business unit historian processingsystems 6, the enterprise network 9, the host processing system 11, theuser processing systems 12, and/or the outside business processingsystem 13 may include the digital and/or analog system. The system mayhave components such as a processor, storage media, memory, input,output, communications link (wired, wireless, pulsed mud, optical orother), user interfaces, software programs, signal processors (digitalor analog) and other such components (such as resistors, capacitors,inductors and others) to provide for operation and analyses of theapparatus and methods disclosed herein in any of several mannerswell-appreciated in the art. It is considered that these teachings maybe, but need not be, implemented in conjunction with a set ofnon-transitory computer executable instructions stored on a computerreadable medium, including memory (ROMs, RAMs), optical (CD-ROMs), ormagnetic (disks, hard drives), or any other type that when executedcauses a computer to implement the method of the present invention.These instructions may provide for equipment operation, control, datacollection and analysis and other functions deemed relevant by a systemdesigner, owner, user or other such personnel, in addition to thefunctions described in this disclosure.

Further, various other components may be included and called upon forproviding for aspects of the teachings herein. For example, atransmitter, receiver, transceiver, antenna, controller, optical unit,electrical unit or electromechanical unit may be included in support ofthe various aspects discussed herein or in support of other functionsbeyond this disclosure.

Elements of the embodiments have been introduced with either thearticles “a” or “an.” The articles are intended to mean that there areone or more of the elements. The terms “including” and “having” areintended to be inclusive such that there may be additional elementsother than the elements listed. The conjunction “or” when used with alist of at least two terms is intended to mean any term or combinationof terms. The terms “first” and “second” are used to distinguishelements and are not used to denote a particular order. The term“configured” relates to one or more structural limitations of a devicethat are required for the device to perform the function or operationfor which the device is configured.

The flow diagrams depicted herein are just examples. There may be manyvariations to these diagrams or the steps (or operations) describedtherein without departing from the spirit of the invention. Forinstance, the steps may be performed in a differing order, or steps maybe added, deleted or modified. All of these variations are considered apart of the claimed invention.

The preferred forms of the invention described above are to be used asillustration only, and should not be used in a limiting sense tointerpret the scope of the present invention. Modifications to theexemplary embodiments, set forth above, could be readily made by thoseskilled in the art without departing from the spirit of the presentinvention.

What is claimed is:
 1. A method for aggregating and evaluating data of equipment operated by a plurality of business units, the method comprising: sensing parameters of the equipment using a sensor to provide sensor data; receiving the sensor data using a plurality of business unit historian processing systems, each business unit historian processing unit being associated with each of the business units in the plurality of business units and configured to label equipment being monitored by the sensor with a general description and a specific description that is more specific than the general description; transmitting the sensor data to a host processing system via an enterprise network of a parent business of the plurality of business units; transmitting equipment data from an outside business processing system of an outside business that is not affiliated with the parent business to the host processing system via the enterprise network; aggregating (i) the sensor data received from each of the business unit historian processing systems associated with each of the business units and (ii) the equipment data into a data base using the host processing system; evaluating the sensor data and the equipment data using the host processing system to provide an equipment evaluation for the equipment associated with each business unit using the host processing system; receiving a request, using the host processing system, for the sensor data, the equipment data, and the equipment evaluation associated with specific equipment at a specific business unit from a user using a user interface that implements a graphical user interface (GUI), the GUI comprising an image mimicking the equipment, the user processing system comprising a search engine configured to search for monitored equipment using at least one of the general description and the specific description; and transmitting the sensor data, the equipment data, and the equipment evaluation associated with the specific equipment at the specific business unit to the user processing system in accordance with the request.
 2. The method according to claim 1, further comprising transmitting the sensor data to the outside business processing system, wherein the outside business processing system evaluates the sensor data and provides an outside equipment evaluation as the equipment data.
 3. The method according to claim 1, wherein evaluating comprises comparing the sensor data or the equipment data to a threshold value.
 4. The method according to claim 3, further comprising initiating an alert signal if the sensor data or the equipment data exceed the threshold value.
 5. The method according to claim 4, further comprising transmitting the alert signal to the user processing system.
 6. The method according to claim 3, further comprising initiating a work order to repair or service the equipment corresponding to the sensor data or the equipment data if the sensor data or the equipment data exceed the threshold value. The method according to claim 6, further comprising transmitting the work order to the business unit having the equipment corresponding to the sensor data or the equipment data.
 8. The method according to claim 7, further comprising repairing or servicing the equipment corresponding to the sensor data or the equipment data in accordance with the work order.
 9. The method according to claim 1, wherein each of the business unit historian processing systems is updated with latest sensor data and latest equipment data in real time.
 10. The method according to claim 1, wherein the general description comprises a function of the corresponding equipment and the specific description comprises a make and model of the corresponding equipment.
 11. The method according to claim 1, further comprising performing a search of the business unit historian processing system using the search engine in the host processing system in response to a request by a user using the user processing system.
 12. A global monitoring system for aggregating and evaluating data of equipment operated by a plurality of business units, the system comprising: a plurality of sensors configured to sense parameters of the equipment to provide sensor data; a plurality of business unit historian processing systems configured to receive the sensor data, each business unit historian processing system being associated with each of the business units in the plurality of business units and configured to label equipment being monitored by the sensor with a general description and a specific description that is more specific than the general description; an enterprise network of a parent business of the plurality of business units, the enterprise network being configured to communicate with the plurality of business unit historian processing systems; a host processing system in communication with the enterprise network and configured to receive the sensor data from each of the business unit historian processing systems and equipment data from an outside processing system of an outside business that is not affiliated with the parent business; a user processing system in communication with the host processing system via the enterprise network and comprising a graphical user interface (GUI), the GUI comprising an image mimicking the equipment, the user processing system comprising a search engine configured to search for monitored equipment using at least one of the general description and the specific description; wherein the host processing system is further configured to: aggregate (i) the sensor data received from each of the business unit historian processing systems associated with each of the business units and (ii) the equipment data into a data base; evaluate the sensor data and the equipment data to provide an equipment evaluation for the equipment associated with each business unit using the host processing system; receive a request for the sensor data, the equipment data, and the equipment evaluation associated with specific equipment at a specific business unit from a user using the user processing system; and transmit the sensor data, equipment data, and equipment evaluation associated with the specific equipment at the specific business unit to the user processing system in accordance with the request.
 13. The global monitoring system according to claim 12, wherein the enterprise network is further configured to transmit the sensor data to the outside business processing system, wherein the outside business processing system evaluates the sensor data and provides an outside equipment evaluation as the equipment data.
 14. The global monitoring system according to claim 12, wherein the host processing system is further configured to compare the sensor data or the equipment data for specific equipment to a threshold value.
 15. The global monitoring system according to claim 14, wherein the host processing system is further configured to initiate an alert signal if the sensor data or the equipment data for specific equipment exceeds the threshold value.
 16. The global monitoring system according to claim 15, wherein the host processing system is further configured to transmit the alert signal to the user processing system.
 17. The global monitoring system according to claim 15, wherein the host processing system is further configured to initiate a work order to repair or service the specific equipment corresponding to the sensor data or the equipment data if the sensor data or the equipment data exceeds the threshold value.
 18. The global monitoring system according to claim 17, wherein the host processing system is further configured to transmit the work order to the business unit having the specific equipment corresponding to the sensor data or the equipment data. 